Filter element with improved dust loading
Embodiments disclosed herein relate to a pleated filter element having filter media having a downstream layer of filter material and an upstream layer of fibers. A spacing structure defines a void space between the upstream layer of fibers and the downstream layer of filter material.
1 . A filter element comprising:
filter media in a pleated configuration having a first set of pleat folds forming an upstream face and a second set of pleat folds forming a downstream face, the filter media having a perimeter region, the filter media comprising:
a downstream layer of filter material in a corrugated configuration defining peaks and valleys; and
an upstream layer of fibers extending across the peaks of the downstream layer of filter material, wherein a void space is defined between the downstream layer of filter material and the upstream layer of fibers, and the upstream layer of fibers has less than 10% solidity; and
a frame component secured to the perimeter region of the filter media.
2 . The filter element of claim 1 , wherein the downstream layer of filter material has a capture efficiency of at least 10%.
3 . The filter element of claim 1 , wherein the upstream layer of fibers is not self-supporting.
4 . The filter element of claim 1 , wherein the downstream layer of filter material defines corrugations having a mean corrugation depth of greater than 0.23 mm.
5 . The filter element of claim 1 , wherein the downstream layer of filter material is self-supporting.
6 . A method of constructing a filter element, the method comprising:
creating a spacing structure on a layer of filter material;
depositing a layer of fibers across the spacing structure of the filter material to form filter media,
wherein a void space is defined between the filter material and the layer of fibers;
pleating the filter media to define a first set of pleat folds and a second set of pleat folds, wherein
the first set of pleat folds form an upstream face and the second set of pleat folds form a downstream face; and
securing a perimeter region of the filter media to a frame component.
7 . The method of claim 6 , wherein the layer of filter material has a capture efficiency of at least 10%.
8 . The method of claim 6 , wherein creating the spacing structure comprises forming corrugations in the layer of filter material.
9 . The method of claim 6 , wherein the layer of filter material is corrugated to have a mean corrugation depth of greater than 0.23 mm.
10 . The method of claim 6 , wherein creating the spacing structure comprises depositing a spacing structure on an upstream surface of the layer of filter material.
11 . A filter element comprising:
filter media in a pleated configuration having a first set of pleat folds forming an upstream face and a second set of pleat folds forming a downstream face, the filter media having a perimeter region, the filter media comprising:
a downstream layer of filter material, wherein the downstream layer of filter material has a capture efficiency of at least 10%; and
an upstream layer of fibers, wherein the upstream layer of fibers has a solidity of less than 10%; and
a spacing structure defining a mean void distance between the upstream layer of fibers and the downstream layer of filter material greater than 0.11 mm; and
a frame component secured to the perimeter region of the filter media.
12 . The filter element of claim 1 , wherein the spacing structure comprises protrusions from the downstream layer of filter material in a direction perpendicular to a length and a width of the filter media.
13 . The filter element of claim 11 , wherein the spacing structure includes corrugations defined by the downstream layer of filter material.
14 . The filter element of claim 11 , wherein the spacing structure includes embossments defined by the downstream layer of filter material.
15 . The filter element of claim 11 , wherein the spacing structure includes deposits disposed between the upstream layer of fibers and the downstream layer of filter material.
16 . The filter element of claim 11 , wherein the upstream layer of fibers is not self-supporting.
17 . The filter element of claim 11 , wherein the upstream layer of fibers is non-corrugated.
18 . The filter element of claim 11 , wherein the downstream layer of filter material is non-corrugated.
19 . The filter element of claim 11 , wherein the downstream layer of filter material is self-supporting.
20 . The filter media of claim 11 , wherein the mean void distance between the upstream layer of fibers and the downstream layer of filter material is less than 1.0 mm.